Corner form/flatwall form release system

ABSTRACT

Systems and methods are provided for separating one or more forms from a hardened material is provided. The system includes a support structure, a securing mechanism, coupled to the support structure, wherein the securing mechanism is configured to secure the system to the one or more forms, and a threaded rod, threaded through an opening in the support structure, wherein the threaded rod is configured to apply pressure to the hardened material.

CLAIM OF PRIORITY

This application is a United States non-provisional application andclaims no priority to any previous patent or patent application.

FIELD OF THE EMBODIMENTS

This invention relates to building construction tools and, inparticular, to tools for removing forms from cement and concrete.

BACKGROUND OF THE EMBODIMENTS

Cement and concrete are widely used in the construction of buildings.Oftentimes, wet concrete is poured into forms such that, when ithardens, it takes the internal shape of the forms. Once the concretehardens, the forms are removed.

Removal of the forms can be a difficult process, since it can be a veryarduous process to separate the form from the hardened concrete. A greatdeal of force is thus often necessary to cause the separation. Thisforce is often applied with crowbars. The presently used methods ofcausing this separation can cause damage to the forms and/or the newlybuilt concrete structures, can be time consuming, and can be unsafe.Labor must stand on top of the newly formed structure to try to pry theform from the structure which, depending on the height of the structure,can be illegal. This practice is banned if caught companies may be finedfor this behavior, and people may be hurt during the form removalprocess. Using present methods, companies must therefore invest inexpensive safety equipment in order to be compliant with relevant safetylaws.

For at least these reasons, a simple and safe system and method ofremoving forms from hardened concrete structures is thus needed.

Examples of related art are described below:

U.S. Pat. No. 6,817,590 generally describes a method and tool forremoving modular concrete forms from underlying rigid concrete. The toolincludes a lever end, a fulcrum, and a claw end having a notchparticularly adapted to engage a knob that protrudes from a surface ofthe modular concrete form. The method includes engaging the claw end ofthe tool with the knob, abutting the fulcrum against rigid concreteadjacent the modular form, and exerting a force on the lever end in thedirection of the adjacent rigid concrete.

U.S. Pat. No. 7,086,640 generally describes a mechanical assembly forpulling the form work away from a concrete structure after the concretestructure has cured. The form work is typically wood or steel andrequires a large mechanically force to free it from the concretestructure. The form puller assembly includes a lever assembly, a fulcrumassembly, and a form pulling assembly. The user pulls down on theopposite end of the lever assembly generating a mechanical forcesufficient to free the form work from the concrete structure. Also, themechanical assembly may include at least one embedded element extractingassembly for removing vertically oriented elements embedded in the soiland/or concrete.

U.S. Pat. No. 4,102,527 generally describes a handtool particularlyadapted to engage concrete forms for prying the same loose from theconcrete after setting. The tool includes a gripping mechanism carriedon a tool frame, the gripper mechanism enabling the lip portion of theconcrete form to be gripped or clamped during the prying operations tomaintain the engagement of the tool with the concrete form. The toolframe includes a support member for the gripper mechanism extendingtransversely to the tool handle which provides leverage for prying theform while it is engaged with the gripper mechanism. The grippermechanism consists of a self-engaging cam clamp element pivotallysupported and spring-biased to the engaging position with a releasehandle provided for releasing the grip from the form.

U.S. Pat. No. 3,690,613 generally describes securing means for aconcrete wall form including a flat tie rod having means at its endsections for attachment to the form sides so that the medial section ofthe tie rod spans the form and becomes embedded in the concrete which ispoured between the form sides, thus leaving outwardly projecting tie rodend sections. Elongated sleeve cones surround such tie rod end sectionsand have their inner ends drivingly connected to the same at regions inthe immediate vicinity of the tie rod breakbacks, and also havetorque-application facilities at their exposed outer ends to that themanual application of torque to the sleeve cones will impart a radialtear or shear effect at the breakbacks to thus free the projecting tierod end sections.

U.S. Pat. No. 4,284,014 generally describes a safe rigidly andpermanently mounted in an opening in a concrete wall or floor. Twointerfitting sleeves co-operating in a pre-oriented, rigid relationshipwith each other and the surface bordering the opening to precludeunauthorized removal. A container element is assembled to one of thesleeves. To retard “sweating” or the accumulation of moisture in thecontainer and to obviate corrosion development, a rigid plastic, such aspolyvinyl chloride, is used for container fabrication. A cover isprovided which is releasably secured in close fitting relationship toone of the sleeves, capturing a cover plate therebetween in pre-selectedorientation adjacent the safe mouth. The co-operation between the cover,the cover plate and the interfitting sleeves maximizes safe security andprecludes extraction from or pushing through the opening in the wall orfloor.

U.S. Pat. No. 5,031,879 generally describes a stake extraction implementfor primary utilization with respect to stakes used for concrete forms.The stake extraction implement is composed of an elongate member,incorporating a handle portion and a curved portion, and a pivotallyconnected gripper tool, incorporating a pair of jaws. When a stake is tobe extracted, the curved portion of the elongate member is placed uponthe adjacent concrete form and the jaws of the gripper tool are alignedto rest upon the sides of the subject stake. According to the method ofuse disclosed, as a lever movement of the handle portion is effected,effortless extraction of the stake from the ground is made possible byautomatic clamping of the jaws of the gripper tool onto the stake, thestake having been nailed to the concrete form notwithstanding. The stakepulling implement is structured to permit user selection of either afirst class or second class lever mode of operation, and two types ofjaw members for the gripper tool are disclosed.

U.S. Pat. No. 7,581,709 generally describes a system of interconnectingstructural components for supporting and forming suspended concreteslabs that allow removal of form panels without disturbing the slabsupport posts (shores). Additional features of the system accommodatechanges in suspended slab thickness, horizontal slab dimensions that arenot multiples of the basic component dimensions, slab edge cantileveredform panels, attachment to walls and remote manipulation of form panelsfrom the floor below using an erection staff. The primary systemcomponents are panels, support posts, telescopic beams, adjustablehanger connections, wall hangers, wall beams, raking shore assembliesand erection/stripping staffs. Form panels are directly supported by theshores without the use of an intermediate member (usually a beam) thatis common practice in the concrete forming industry. The system reducesthe number of required components that in turn reduces the capital costto the user and improves his labor efficiency and quality of theconcrete surface.

U.S. Pat. No. 9,309,688 generally describes a post anchoring supportdevice comprising a ground anchor having a shaft with a threaded upperportion terminating in an upper end that may be engaged and rotated by adrive tool for rotating the shaft about a vertical axis, and a lowerportion for insertion into the ground, and a post receiving brackethaving base with a vertically oriented internally threaded portionadapted to receive the externally threaded portion of the shaft, asupport portion defining a support surface for abutting the end of thepost, vertical planar walls extending above the support surface, eachplanar wall having an inside surface for abutting a side of the post,and each planar wall defining a plurality of vertically orientedelongate holes and having a raised portion on the outside surfaceadjacent each elongate hole adapted to abut a lower surface of a head ofa fastener passing through the elongate hole and into the post to allowthe fastener to travel within the elongate hole upon the application ofa vertically force to the post anchoring support device sufficient toovercome a coefficient of friction between the head of the fastener andthe raised portion.

U.S. Pat. No. 9,458,591 generally describes piling apparatus and methodsfor installing a reinforced concrete piling apparatus into the groundwithout the use of a pile driver or an auger. A helical screw anchor andcoupling device are used to pull pipe sections into the ground. Apreassembled reinforcing rod cage is placed into the pipe sections inthe ground. Wet concrete is poured into the pipe sections to encase thereinforcing rod cage. The pipe sections are then removed. Removal of thepipe sections from the helical screw anchor is accomplished using thecoupling device.

U.S. Pat. No. 9,631,392 generally describes a post anchoring supportdevice comprising a ground anchor having a shaft with a threaded upperportion terminating in an upper end that may be engaged and rotated by adrive tool for rotating the shaft about a vertical axis, and a lowerportion for insertion into the ground, and a post receiving brackethaving a base with an elongate aperture adapted to receive theexternally threaded portion of the shaft, a support portion defining asupport surface for abutting the end of the post, vertical planar wallsextending above the support surface, each planar wall having an insidesurface for abutting a side of the post, and each planar wall defining aplurality of vertically oriented elongate holes and having a raisedportion on the outside surface adjacent each elongate hole adapted toabut a lower surface of a head of a fastener passing through theelongate hole and into the post to allow the fastener to travel withinthe elongate hole upon the application of a vertically force to the postanchoring support device sufficient to overcome a coefficient offriction between the head of the fastener and the raised portion.

U.S. Pat. No. 9,746,019 generally describes a securement device thatincludes a pair of plungers movable within a housing. The plungers actas quick lock mechanism to engage and secure a threaded rod (or otherobject) that passes into a hole that runs through the housing. Theplungers are spring-biased to position themselves toward so as toprovide a radially inward force, for example to engage a threaded rod ordevice in the through hole in the housing. A spring within the housingpresses the plunger pieces toward a portion of the housing where theouter surfaces engage other surfaces to push the plungers inward. Thedevice includes a disengagement feature or mechanism that is used topush the plunger pieces out of engagement with the threaded rod. Thedisengagement feature may include a disengagement tool, and may includewings, such as on the plungers or on carriers for the plungers, thatprotrude out of the housing.

U.S. Patent Publication No. 2016/0312460 generally describes a deviceand method in which, in a load-bearing concrete vertical building part,particularly a support, with an upper support area for aload-transferring connection to a concrete horizontal building partthereabove, in which the vertical building part includes reinforcementswith reinforcement rods extending essentially vertically beyond theupper support area, an upper section of the vertical building partabutting the upper support area is embodied as a thermal insulationelement for the thermal decoupling of the vertical building part fromthe horizontal building. The upper section forming the thermalinsulation element is made at least partially from a compressive loadtransferring and thermally insulating material, particularlylight-weight concrete, and reinforcement rods extending beyond the uppersupport area are made from a fiber composite material, and extendthrough the upper section of the vertical building part forming thethermal insulation element essentially vertically to the lower sectionof the vertical building part located underneath thereof.

International Patent Publication No. WO2004065722A1 generally describesa system of interconnecting structural components for supporting andforming suspended concrete slabs that allow removal of form panelswithout disturbing the slab support posts. Additional features of thesystem accommodate changes in suspended slab thickness, horizontal slabdimensions that are not multiples of the basis component dimensions,slab edge cantilevered form panels, attachment to walls and remotemanipulation of form panels from the floor below using an erectionstaff. The primary system components are panels, support posts,telescopic beams, adjustable hanger connections, wall hangers, wallbeams, raking shore assemblies and erection/stripping staffs. Formpanels are directly supported by the shores without the use of anintermediate member (usually a beam) that is common practice in theconcrete forming industry. The system reduces the number of requiredcomponents that in turn reduces the capital cost to the user andimproves his labor efficiency and quality of the concrete surface.

International Patent Publication No. WO2006124079A1 generally describesa wheeled slab removal device, for concrete or other materials, grabsand lifts a slab from a lower level to a higher lever, without droppingthe wheels into the hole/space left by removing the slab. The device mayinclude a pivotal jaw system that tightens its grasp on the slab as theweight of the slab pivots the jaw. An elongated central support/handleprovides leverage, whereby a single operator may lift, pivot, and wheelthe slab away, without the need to hoist the slab removal device andslab out of the hole left by the slab. Preferred versions of the devicehave a carry plate, and a pivotal jaw for grasping the slab betweenthem, wherein the distance between the carry plate and the jaw may beadjusted, for example, by extending the longitudinal axis of the centralsupport. In use, the preferred device is placed over the slab, thedistance between the jaw and carry plate is shortened to grasp the slab,and the device handle is lifted to pivot the slab, at which time the jawsystem tightens even more due to the weight of the slab pivoting the jawand lengthening the central support. At generally the same time, thewheel system pivots to move the fulcrum for the device to a position ontop of the adjacent concrete or other structure higher than the originalposition of the slab being removed.

International Patent Publication No. WO2016041015A1 generally describesa device for clamping a piece of formwork. The device comprises a barhaving an end for attachment to a body. The device comprises a jawmounted on the bar and for receiving the piece of formwork, the jawbeing movable along the bar.

None of the art described above addresses all of the issues that thepresent invention does.

SUMMARY OF THE EMBODIMENTS

According to an aspect of the present invention, a system for separatingone or more forms from a hardened material is provided. The systemincludes a support structure, a securing mechanism, coupled to thesupport structure, wherein the securing mechanism is configured tosecure the system to the one or more forms, and a threaded rod, threadedthrough an opening in the support structure, wherein the threaded rod isconfigured to apply pressure to the hardened material.

It is an object of the present invention to provide the system forseparating one or more forms from the hardened material, wherein thehardened material is selected from the group consisting of: cement; andconcrete.

It is an object of the present invention to provide the system forseparating one or more forms from the hardened material, wherein thesecuring mechanism is further configured to secure the system to the oneor more forms using a nut and bolt.

It is an object of the present invention to provide the system forseparating one or more forms from the hardened material, wherein thethreaded rod further includes a foot portion.

It is an object of the present invention to provide the system forseparating one or more forms from the hardened material, wherein thefoot portion is configured to rest against the hardened material.

It is an object of the present invention to provide the system forseparating one or more forms from the hardened material, wherein thethreaded rod further includes a knob section, the knob section beingconfigured to assist in threading the threaded rod through the openingin the support structure.

It is an object of the present invention to provide the system forseparating one or more forms from the hardened material, wherein thesecuring mechanism has an adjustable length.

According to another aspect of the present invention, a method forseparating one or more forms from a hardened material is provided. Themethod includes securing one or more release systems to the one or moreforms, each of the one or more release systems including: a supportstructure; a securing mechanism, coupled to the support structure,wherein the securing mechanism is configured to secure the system to theone or more forms; and a threaded rod, threaded through an opening inthe support structure, wherein the threaded rod is configured to applypressure to the hardened material. The method further includes threadingthe threaded rod through the opening in the support structure until theone or more forms separates from the hardened material.

It is an object of the present invention to provide the method forseparating one or more forms from the hardened material, wherein thehardened material is selected from the group consisting of: cement; andconcrete.

It is an object of the present invention to provide the method forseparating one or more forms from the hardened material, wherein thesecuring further includes securing the system to the one or more formsusing a nut and bolt.

It is an object of the present invention to provide the method forseparating one or more forms from the hardened material, wherein thethreaded rod further includes a foot portion.

It is an object of the present invention to provide the method forseparating one or more forms from the hardened material, wherein thefoot portion is configured to rest against the hardened material.

It is an object of the present invention to provide the method forseparating one or more forms from the hardened material, wherein thethreaded rod further includes a knob section, the knob section beingconfigured to assist in threading the threaded rod through the openingin the support structure.

It is an object of the present invention to provide the method forseparating one or more forms from the hardened material, wherein thethreading further includes rotating the knob.

It is an object of the present invention to provide the method forseparating one or more forms from the hardened material, wherein thesecuring mechanism has an adjustable length and can freely rotate toalign/be compatible with existing modular forms.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a device for separating forms from hardened concretestructures, according to an embodiment of the present invention.

FIG. 2 shows the device of FIG. 1 in use with a form and a hardenedconcrete structure, according to an embodiment of the present invention.

FIG. 3 shows a device for separating forms from hardened concretestructures, according to an embodiment of the present invention.

FIG. 4 shows the device of FIG. 3 in use with a form and a hardenedconcrete structure, according to an embodiment of the present invention.

FIG. 5 shows a flowchart of a method for separating forms from hardenedconcrete structures, according to an embodiment of the presentinvention.

FIG. 6 shows a form having multiple devices for separating forms fromhardened concrete structures, according to an embodiment of the presentinvention.

FIG. 7 shows a fully constructed form having one or more channels forsecuring one or more devices for separating forms from hardened concretestructures, according to an embodiment of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The preferred embodiments of the present invention will now be describedwith reference to the drawings. Identical elements in the variousfigures are identified with the same reference numerals.

Reference will now be made in detail to each embodiment of the presentinvention. Such embodiments are provided by way of explanation of thepresent invention, which is not intended to be limited thereto. In fact,those of ordinary skill in the art may appreciate upon reading thepresent specification and viewing the present drawings that variousmodifications and variations can be made thereto.

Referring now to FIGS. 1-2, a device 100 for separating one or moreforms 116 from hardened concrete structures 102 is illustrativelydepicted, in accordance with an embodiment of the present invention. Itis noted, however, that any suitable hardenable material such as, e.g.,cement, may be used in addition to, or instead of, concrete in theformation of the hardened structures 102.

According to an embodiment, the device 100 includes a support structure104, a threaded rod 106 coupled to the support structure 104, and asecuring mechanism 108 coupled to the support structure 104.

According to an embodiment, the securing mechanism 108 includes anopening 114, enabling the securing mechanism 108 to secure the supportstructure 104 to a form 116. According to an embodiment, the securingmechanism 108 is secured to the form 116 via a nut and bolt 118. It isnoted, however, that the securing mechanism 108 may secure the supportstructure 104 to the form using any suitable means, while maintainingthe spirit of the present invention.

According to an embodiment, the threaded rod 106 is threaded through athreaded opening 120 in the support structure 104. According to anembodiment, the threaded rod 106 includes a knob portion 110 and a footportion 112. According to an embodiment, the foot portion 112 restsagainst the hardened concrete structure 102. The threaded rod 106 isthreaded through the support structure 104, causing the foot portion 112to apply force against the concrete structure 102, causing a separatingforce between the hardened concrete structure 102 and the form 116.According to an embodiment, once a sufficient force has been applied tothe hardened concrete structure 102, the form 116 separates from thehardened concrete structure 102. According to an embodiment, thethreaded rod 106 is threaded through the opening 120 by rotating theknob portion 110. It is noted, however, that any suitable means may beused to thread the threaded rod, while maintaining the spirit of thepresent invention.

Referring now to FIGS. 3-4, a device 300 for separating one or moreforms 116 from hardened concrete structures 102 is illustrativelydepicted, in accordance with an embodiment of the present invention.

According to the embodiment as shown in FIG. 4, the form 116 and thehardened concrete structure 102 is not linear. In the embodiment shownin FIG. 4, the structure 102 and form 116 are bent at a right angle. Itis noted, however, that the structure 102 and form 116 may be at anysuitable shape, while still maintaining the spirit of the presentinvention.

According to an embodiment, depending on the shape of the structure 102and the forms 116, two or more devices 300 may need to be used toseparate the forms 116 from the structure 102. According to anembodiment, the two or more devices 300 are positioned against the forms116 in such a way that, when the threaded rod 106 is threaded throughthe opening 120 by rotating the knob portion 110, a separating force isproduced between the hardened concrete structure 102 and the form 116causing the form 116 to separate from the hardened concrete structure102.

According to an embodiment, the securing mechanism 108 may have anadjustable length. The adjustable length may be due to the use of athreaded bolt 122 and/or any other suitable means. According to anembodiment, the securing mechanism 108 can freely rotate to align/becompatible with existing modular forms 116

It is noted that, in any of the embodiments of the present invention,the device 100, 300 may be placed in any suitable location to cause anappropriate separating force between the form 116 and the structure 102.

Referring now to FIG. 5, a flowchart of a method 500 for separatingforms from hardened concrete structures is illustratively depicted, inaccordance with an embodiment of the present invention.

At step 505, one or more forms 116 are set in place, wherein the one ormore forms 116 are configured such that a liquid hardening material maybe poured into the forms 116. At step 510, the liquid hardening materialis poured into one or more gaps formed by the placement of the forms116. According to an embodiment, the liquid hardening material is liquidconcrete. It is noted, however, that any suitable hardening material maybe used, while still maintaining the spirit of the present invention. Atstep 515, the liquid hardening material hardens, forming the hardenedstructure 102 in the shape of the cavity of the one or more forms 116into which the liquid hardening material was poured. According to anembodiment, the shape is a wall. However, it is noted that the shape maybe any suitable shape, while maintaining the spirit of the presentinvention.

At step 520, after the liquid hardening material hardens, the releasesystem 100, 300 is attached to the form 116 using a threaded rod andbolt 118. According to an embodiment, the foot 112 of the release system100, 300 rests flat on the hardened structure 102. According to anembodiment, the release system 100, 300 is positioned and configured toapply a force perpendicular to the hardened structure 102, thus pushingthe form 116 away from the hardened structure 102. According to anembodiment, the release system 100, 300 is attached to the form 116prior to the curing and/or hardening. According to an embodiment, therelease system 100, 300 is secured to channels 604 (shown in FIGS. 6-7)in the form 116. According to an embodiment, the release system 100 issecured to the form 116 using one or more securing mechanisms such as,e.g., one or more pins 606 (shown in FIG. 6).

At step 525, the threaded rod 106 of the release system 100, 300 isfurther threaded through an opening 120 of a support structure 104 ofthe release system 100, 300, increasing the force of the foot 112 on thenewly constructed hardened structure 102 to push the form 116 away fromthe hardened structure 102. At step 530, the pushing force applied bythe foot 112 causes the form to separate from the hardened structure.According to an embodiment, prior to applying the pushing force, one ormore shear bolts 602 (shown in FIG. 7) are removed. According to anembodiment, concrete ties 608 (shown in FIG. 6) are positioned after theremoval of the shear bolts 602.

The present release system improves upon the existing systems andmethods in several ways. The present release system decreases the amountof time needed to separate forms from hardened structures. Since manyworkers are paid by the hour, decreasing the amount of time cansignificantly reduce construction costs. The present release systemfurther reduces wear on expensive modular forms for use in construction.By decreasing wear, the forms can be used more often, decreasing repaircosts and decreasing costs to build new forms. Furthermore, the presentrelease system provides a system and method for removing forms fromhardened structures that is safer than previous systems and methods.This can help decrease injuries, which can be expensive to both theworkers and the employers.

When introducing elements of the present disclosure or the embodiment(s)thereof, the articles “a,” “an,” and “the” are intended to mean thatthere are one or more of the elements. Similarly, the adjective“another,” when used to introduce an element, is intended to mean one ormore elements. The terms “including” and “having” are intended to beinclusive such that there may be additional elements other than thelisted elements.

Although this invention has been described with a certain degree ofparticularity, it is to be understood that the present disclosure hasbeen made only by way of illustration and that numerous changes in thedetails of construction and arrangement of parts may be resorted towithout departing from the spirit and the scope of the invention.

What is claimed is:
 1. A system for separating one or more forms from ahardened material, comprising: a support structure; a securingmechanism, coupled to the support structure, wherein the securingmechanism is configured to secure the system to the one or more forms;and a threaded rod, threaded through an opening in the supportstructure, wherein the threaded rod is configured to apply pressure tothe hardened material.
 2. The system as recited in claim 1, wherein thehardened material is selected from the group consisting of: cement; andconcrete.
 3. The system as recited in claim 1, wherein the securingmechanism is further configured to secure the system to the one or moreforms using a nut and bolt.
 4. The system as recited in claim 1, whereinthe threaded rod further includes a foot portion.
 5. The system asrecited in claim 4, wherein the foot portion is configured to restagainst the hardened material.
 6. The system as recited in claim 1,wherein the threaded rod further includes a knob section, the knobsection being configured to assist in threading the threaded rod throughthe opening in the support structure.
 7. The system as recited in claim1, wherein the securing mechanism has an adjustable length.
 8. A methodfor separating one or more forms from a hardened material, comprising:securing one or more release systems to the one or more forms, each ofthe one or more release systems including: a support structure; asecuring mechanism, coupled to the support structure, wherein thesecuring mechanism is configured to secure the system to the one or moreforms; and a threaded rod, threaded through an opening in the supportstructure, wherein the threaded rod is configured to apply pressure tothe hardened material; and threading the threaded rod through theopening in the support structure until the one or more forms separatesfrom the hardened material.
 9. The method as recited in claim 8, whereinthe hardened material is selected from the group consisting of: cement;and concrete.
 10. The method as recited in claim 8, wherein the securingfurther includes securing the system to the one or more forms using anut and bolt.
 11. The method as recited in claim 8, wherein the threadedrod further includes a foot portion.
 12. The method as recited in claim11, wherein the foot portion is configured to rest against the hardenedmaterial.
 13. The method as recited in claim 1, wherein the threaded rodfurther includes a knob section, the knob section being configured toassist in threading the threaded rod through the opening in the supportstructure.
 14. The method as recited in claim 13, wherein the threadingfurther includes rotating the knob.
 15. The method as recited in claim8, wherein the securing mechanism has an adjustable length.